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Components for battery production

Next level battery manufacturing - particle-free. Lubrication-free. IPA-approved

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With the growing demand for electric cars, the need for high-quality lithium-ion batteries is also increasing. Battery manufacturing involves several critical components that are necessary for the production of batteries. Each component must contribute to maximising quality, safety and performance. With igus components such as plain bearings and linear technology as well as energy chains, efficiency can be increased, downtimes reduced and the automation of battery production plants improved.

Ideally, battery production takes place with minimum humidity and the greatest possible freedom from particles. Our cleanroom-compatible and dissipative cable guide systems for the dry cleanroom support this process and ensure reliable performance in battery production.

Areas of application: Material handling, electrode production, cell assembly, sealing and further processing as well as control and inspection

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igus products for battery production

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battery_fullInnovative products for battery productionZu KabelführungssystemenProducts for the dry cleanroomInformation material: Dry cleanroom test laboratory

Innovative products for battery production

Certified cable guide systems

Certified cable guide systems for the dry cleanroom
To the dry cleanroom products

Slewing ring bearing PRT-04-100

Slewing ring bearing PRT-04-100 for the dry cleanroom
To the slewing ring bearing PRT-04

xiros conveyor roller

xiros ball bearings
To the PVC conveyor roller

iglidur plain bearings

Plain bearing iglidur
To the plain bearings

igubal flange mounted bearings

igubal flange mounted bearings
To the flange mounted bearings

iglidur bar stock

iglidur bar stock
To the bar stock

drylin T guide carriage TW-42

drylin linear guides
To the linear guide TW-42

drylin ZLW toothed belt axes

drylin ZLW
To the toothed belt axes

Linear robots

Linear robots
To the linear robots

ReBeL cobot

rebel
To the cobots

Handling of battery cells

The automated handling of battery cells is a key factor in the optimisation of modern production processes. A room linear robot was used in a test setup to efficiently remove battery cells and position them precisely in holders. Working together with employees on the conveyor belt, the system consistently prepares assembled battery packs for the next process stage, reducing manual labour and increasing efficiency.

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Certified products for the dry cleanroom

What is a dry cleanroom?

A dry cleanroom for battery production is a special controlled environment that provides both extremely low humidity and a high level of particle-free air. There, the humidity is reduced to below 1%, often below 1% relative humidity, which corresponds to a dew point of -40°C. This ensures that no condensation takes place and no moisture gets into the materials. This is of great importance in some process steps of battery production because even small amounts of water can lead to battery fires.

Why is dry cleanroom important?

  • Higher product quality: reduced contamination leads to higher quality and reliability of battery cells
  • Longer service life: minimising chemical reaction extends battery life
  • Safer working environment: strict control over hazardous materials increases safety for personnel

Cable guide systems

Cable guide systems are essential for reliable energy and data transmission in dry cleanrooms, which are used in applications such as electrode coating and cell assembly. To ensure that our cable guide systems fulfil the requirements of the dry environment, we have tested them for durability and cleanliness together with the Fraunhofer IPA.

The result: High cleanliness over a test period of 10 months, 15 million double strokes and certification for ISO Class 3 or 4 dry cleanrooms.

Flat cable system e-skin flat

Flat cable system e-skin flat

Easily openable chamber design, hoses or stranding elements quickly replaced

  • Over 15 million double strokes
  • Best possible ISO Class 4 certification
  • No visible wear, abrasion-resistant
To the flat cable system e-skin flat

ESD robot energy supply

Robot energy supply with ESD protection

The triflex TRC energy chains for 3D movement and strain relief are made entirely of ESD material.

  • ESD material tested with over 10 million cycles for the highest requirements
  • ISO Class 4-5 certification
To the ESD robot energy supply system

Energy chain series C6

Energy chain series C6

The C6 for cleanroom applications shows hardly any measurable abrasion, even under high loads

  • For ISO Class 4 applications
  • Very smooth running and high stability thanks to a robust stop-dog system
To the C6 energy chain

Energy chains for high dynamics

E6 energy chain
E6 energy chain series

Two-piece corrugated tubes

Two-part corrugated tubes e-skin
e-skin corrugated tube

Two-part corrugated tubes, ESD

Corrugated tubes e-skin soft ESD
Dissipitive e-skin corrugated tubes

Flat cable system e-skin flat, ESD

Flat cable system e-skin flat esd
e-skin flat ESD

SCARA energy supply, ESD protection

Clean SCARA ESD
Clean SCARA Cable Solution, ESD

Multi-axis energy chain ESD with fibre-rod

TRC ESD with fibre-rod
triflex TRC, ESD
Fibre-rod module for TRC
TPE energy and signal cables

TPE energy and signal cables

Our TPE cables are the perfect solution for energy and signal transmission in demanding battery production. Their abrasion-resistant TPE outer jacket reduces particle emissions and has been tested by the Fraunhofer Institute.

The flexible, resistant material guarantees reliability and durability even in dynamic energy chain applications. The cable material is characterised by its high resistance to mechanical stress, making it ideal for use in sensitive cleanroom environments. In dry environments, the material retains its flexibility as it only releases minimal moisture. This ensures that the outer jacket does not become porous and there is no risk of breakage.

All chainflex cables are specially developed for mobile applications and are tested and inspected in our in-house test laboratory spread over an area of 5,500m². In addition, all chainflex cables have a unique guarantee of up to four years, which emphasises their quality and durability.

To chainflex cables

Tested quality for dry cleanrooms

Cable guide systems

e-skin flat certificate

chainflex cables

Certificate

Slewing ring bearing PRT

Certificate

Fraunhofer IPA certifications for the dry cleanroom

Slewing ring bearings for the cleanroom

Together with the Fraunhofer Institute, we have developed two new certificates that confirm the dry cleanroom suitability of our energy chains in long-term tests. The two new certificates are divided into pre-aging and aging behaviour.

The "pre-aging certificate", which we commissioned for our e-skin soft and E14 energy chain systems, certifies the systems after 15 million double strokes and 10 months in the dry cleanroom. Here we received the best possible cleanroom ISO Class 4 certification (see Table 2).

Two of our cleanroom energy supply systems, the E6.J and the e-skin flat, were tested over a period of 10 months on an endurance machine in the dry cleanroom. They completed over 15 million double strokes. The systems were tested and certified for their cleanroom class every two months. The e-skin flat system withstood the double strokes without any problems and received the best possible ISO cleanroom Class 4 certification. A higher certification is not possible as the test environment (ISO Class 3 dry cleanroom with a relative humidity of <1% corresponding to a dew point of -40°C) is not clean enough. The E6.J was able to maintain this result for four months, but then lost a cleanroom class and finished with ISO Class 5 (see Table 3).

Table 1: STANDARD dry cleanroomv = 0.5 m/s a = 1 m/sv = 1 m/s a = 2 m/sv = 2 m/s a = 4 m/s
E6 (IPA report 2303-1408)ISO 4ISO 4ISO 4
TRC.ESD + fibre-rod (IPA report 2309-1461)ISO 4ISO 4ISO 5
Table 2: PRE-AGEING dry cleanroomv = 0.5 m/s a = 1 m/sv = 1 m/s a = 2 m/sv = 2 m/s a = 4 m/s
SKS28 (IPA report 2411-1575)*ISO 4ISO 4ISO 4
E14 (IPA report 2411-1575)ISO 4ISO 4ISO 4
Table 3: AGEING BEHAVIOUR dry cleanroomTime / double strokes
Time: After running-in phase | double strokes: 0Time: After 2 months | double strokes 3.2 millionTime: After 4 months | double strokes: 5.1 millionTime: After 6 months | double strokes: 7.5 millionTime: After 8 months | double strokes: 10 millionTime: After 10 months | double strokes: 15 million
e-skin*ISO 4ISO 4ISO 4ISO 4ISO 4ISO 4
E6*ISO 4ISO 4ISO 4ISO 5ISO 5ISO 5

*Note: The cleanroom energy chains SKS28, e-skin flat, and E6 are certified to ISO Class 1 cleanroom standards under normal ambient humidity.

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